Water and organic constituent separator system and method

ABSTRACT

A regenerating system, for the removal of water and potentially harmful organic constituents from a hydration fluid used to dehydrate natural gas. The system includes a device to assure positive flow of the water and organic constituent vapor out of the regenerator, to, in turn, control back pressure associated with the regenerator during the distillation process.

This application is a division of application number 08/349,951, filed Dec. 6, 1994 , (status, pending).

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an apparatus for separating moisture, and more particularly water from a glycol regenerator/still which has been removed from, for example, natural gas during the dehydration of same.

2. The Prior Art

Natural gas, when it is drawn from underground sources, often is "contaminated" with water vapor. The presence of such water vapor is undesirable, since it can cause corrosion as well as ice formation in natural gas pipelines.

To remove such water vapor, dehydrators, such as glycol dehydrators have been used to remove the water vapor from the gas. Other forms of dehydrators, which do not absorb the water, or which utilize solutions other than glycol, have also been known in the art.

With respect to the use of glycol, and for example, triethylene glycol, such a solution acts as an absorbent with respect to water vapor. The moist glycol is then later distilled in what is known as a glycol regenerator. After the water is separated from the glycol solution, this "clean" glycol is then reused for further dehydration of natural gas.

Inasmuch as natural gas typically contains various volatile organic compounds (VOCs) such as benzene, toluene, ethyl-benzene, and xylenes (collectively known as BTEX), as well as water, and inasmuch as such organics also become absorbed into the glycol during dehydration, these potentially harmful constituents likewise become separated from the glycol during the distillation process. However, because of the toxicity of the BTEX components and, in turn, the potential danger they may cause if released into the ambient environment, methods have been devised for removing such BTEX from the water during distillation from the glycol solution toward operable and safe use of same.

One such system for removing BTEX from recovered water is shown in Lowell, U.S. Pat. No. 5,209,762, the disclosure of which is incorporated herein by reference. In the Lowell '762 system, the water vapor is passed through a condenser having one or more stages which may be air and/or water cooled. The condensate is then collected in a three phase separator, in which the condensate forms in three distinct layers: on bottom, purified liquid water; in the middle, liquid BTEX; on top, gaseous BTEX. The liquid water may then be passed to a series of one or more strippers, and other subsequent polishing stages, to further reduce the amount of BTEX and other undesirable organic constituent compounds. The liquid BTEX is drained off and recovered--inasmuch as BTEX, in liquid form, has viable commercial uses, such as for fuel. The gaseous BTEX is either emitted into the ambient environment, burned off as waste gas flare, or, alternatively, it is added to the fuel gas used to provide the heat for the glycol regenerator. Accordingly, when the gaseous BTEX compounds are combusted, they are broken down into environmentally more acceptable combustion byproducts.

The Lowell '762 glycol dehydration and BTEX separation systems are disclosed and contemplated as being a combined installation. One problem which may arise during the operation of such a system is that the back pressure of the glycol regenerator column may fluctuate and become too great, impeding flow of the glycol through the regenerator, and of the water/BTEX vapor through the regenerator column. In addition, to having possible slowed flow-through of the water/BTEX vapor, a secondary effect of such variable, uncontrolled back pressure, is the buildup in the regenerator of various deposits which can further accelerate the impediment of flow-through, and build up of further deposits, as well as contributing to the overall degradation of the regenerator structure.

Accordingly, it would be desirable to provide a glycol dehydration system which would include a BTEX separation system which would have an improved flow-through of water/BTEX vapor from the regenerator to the condenser/accumulator stage.

SUMMARY OF THE INVENTION

The present invention is a system for separating water and volatile organic constituent materials recovered during the dehydration of a gas, such as a natural gas, wherein the system includes a dehydrating solution, such as glycol which absorbs water from the natural gas. The system comprises means for distilling water and organic constituent vapor from the glycol solution; means for condensing the water and organic constituent vapor, operably connected to the means for distilling water and organic constituent vapor; means for separating the condensed water and organic constituent vapor into separate constituents of liquid water, liquid organic constituent, and residual gaseous organic constituent; means for positively drawing the water and organic constituent vapor from the distilling means and propelling the water and organic constituent vapor to the condensing means, and in turn, to the separating means, the means for positively drawing the water and organic constituent vapor from the distilling means being operably associated with the separating means and the distilling means.

The invention further comprises conduit means for connecting the distilling means with the condensing means, for the transportation of the water and organic constituent vapor to the condensing means.

In a preferred embodiment of the invention, the means for positively drawing the water and organic constituent vapor from the distilling means further comprises a source of fluid; means for propelling the fluid along a fluid conduit; eductor means operably disposed in the conduit means connecting the distilling means and the condensing means, the fluid conduit connecting the means for propelling the fluid with the eductor means, such that flow of the propelled fluid merges with the flow of the water and organic constituent vapor, and the water and organic constituent vapor become entrained in the propelled fluid, and the water and organic constituent vapor become positively drawn from the distilling means.

The source of fluid preferably is the liquid water in the separating means.

In a preferred embodiment of the invention, the organic constituent comprises hydrocarbon materials, which may include components from at least one of the following: benzene, toluene, ethylbenzene, and xylenes.

The system may further comprise means for controlling the means for positively drawing the water and organic constituent vapor from the distilling means, for regulating the rate of flow of the water and organic constituent vapor. The control means comprises temperature sensing means, operably disposed in the flow path of the water and organic constituent vapor, downstream of the eductor means; valve means operably disposed in the fluid conduit, upstream of the eductor means; processor means, operably connected to the temperature sensing means and the valve means, so as to actuate the valve means to reduce flow when the temperature sensed is less than a predetermined temperature, and to increase flow when the temperature sensed is greater than a predetermined temperature.

The system may also further comprise means for regulating the level of liquid water in the fluid conduit. In particular, the means for regulating the level of liquid water comprises an accumulator operably associated with the separating means; means for sensing the level of water in the accumulator; valve means operably associated with the accumulator; control processor means operably associated with the sensing means and the valve means, operably configured so as to release water from the accumulator when the level therein exceeds a predetermined value.

The invention also comprises a method for separating volatile organic constituent materials from water recovered during the dehydration of natural gas or a similar fuel gas, of the kind employing a dehydrating solution, such as glycol, to absorb water from the natural gas. In a preferred embodiment, the method comprises the steps of:

a) distilling the water and organic constituent laden glycol in distilling means after the glycol has been employed to absorb the water from the natural gas, so as to separate water and organic constituent vapor from the liquid glycol;

b) exerting a propulsive force on the water and organic constituent vapor so as to cause the water and organic constituent vapor to be propelled through and away from the distilling means;

c) conducting the water and organic constituent vapor to a condensing means;

d) conducting the at least partially condensed water and organic constituent vapor from the condensing means to a separating means;

e) separating the at least partially condensed water and organic constituent vapor into at least three constituents including liquid water, liquid organic constituent and gaseous organic constituent.

The method of the present invention may also further comprise the step of retrieving the liquid water and liquid organic constituent for later utilization.

In another preferred embodiment of the invention, the step of exerting a propulsive force on the water and organic constituent vapor further comprises the steps of conducting a pressurized stream of fluid, from a source of fluid, into intersecting relationship with the water and organic constituent vapor, such that the water and organic constituent vapor become entrained in the pressurized stream, and exposing the water and organic constituent vapor to a partial vacuum so as to draw the water and organic constituent vapor from the distilling means.

The method may also comprise the steps of sensing the temperature of the flow of water and organic constituent vapor, downstream of the intersection of the pressurized stream of fluid with the water and organic constituent vapor flow; and controlling the flow of pressurized fluid, so as to increase the flow, if the sensed temperature is higher than a predetermined temperature, and so as to decrease the flow, if the sensed temperature is lower than a predetermined temperature.

Alternatively, the method may further comprise the steps of monitoring the level of fluid in the source of fluid; and controlling release of fluid into the flow of pressurized fluid so as to introduce less fluid when the level of fluid is lower than a predetermined level, and release to a drain fluid, when the level of fluid is higher than a predetermined level.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a prior art glycol dehydration apparatus;

FIG. 2 is a schematic illustration of a prior art BTEX separation apparatus used with the prior art glycol dehydration apparatus of FIG. 1, and illustrating the glycol regenerator of the dehydration apparatus of FIG. 1; and

FIG. 3 is a schematic illustration of a portion of an improved glycol dehydration and BTEX separation apparatus according to the present invention.

BEST MODE FOR PRACTICING THE INVENTION

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will be described herein in detail, a specific embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.

A prior art glycol dehydration system 10 is shown in FIG. 1. Moisture laden natural gas is inletted into absorber 12 at inlet 14. The gas contacts the regenerated glycol in absorber 12 in a known manner, and leaves absorber 12 as dry natural gas at outlet 16. Water and BTEX laden glycol leaves absorber 12 at outlet 18, passing through balance pump 20, to flash tank 22. Balance pump 20 is provided to regulate the flow of regenerated glycol going into absorber 12, as well as the flow of used glycol exiting absorber 12. In flash tank 22, the used glycol is expanded, with light gases, such as methane and propane, being vented at 24. The light gases may be simply burned off, or piped for use in the glycol regenerator 36. The remaining liquid glycol and water will exit flash tank 22 at 26, pass through a filter 28, and proceed to heat exchanger 30, where the liquid glycol and water will pick up heat from the regenerated glycol exiting regenerator 36.

The warmed liquid glycol and water are then conducted at 34 to regenerator 36, which may be fired by natural gas, which may be mixed with the light gases from the flash tank 22, as well as gaseous BTEX from the separator, where they are heated such that the water and BTEX are desorbed, at 38.

The regenerated glycol exits regenerator 36 at 40, and is conducted through heat exchanger 30. After giving off heat to the glycol and water mixture from absorber 12, the regenerated glycol may be circulated through a filter 42, pumped up to appropriate pressure at balance pump 20, and circulated through absorber 12, to complete the glycol circuit.

In prior art BTEX separation system 50 (FIG. 2), regenerator 36 gives off water/BTEX vapor at 38. Regenerator column 37 may include heat exchanger 39 (not shown in FIG. 1 ), having an entrance 41 and exit 43, for preheating the liquid glycol/water mixture after exiting absorber 12, and before expansion in flash tank 22.

The water/BTEX vapor is then, typically, passed through a steam stripper 44, as is known in the prior art, and then through a condenser 46, which, as in the illustrated embodiment, may comprise an air cooled stage 48 and a water cooled stage 49. The condensates are conducted to a three phase separator 52, in which the condensates divide into a lowermost layer of water, a center layer of liquid BTEX, and an upper layer of gaseous BTEX. The liquid water may be circulated through stripper 44, for further polishing, cooled at cooler 54, and pumped off for other use, at 56. The liquid BTEX and other organic materials are separated from the liquid water at 58, for collection and possible use, for example, as a liquid fuel material. The gaseous BTEX may then simply be vented, at 60, or drawn, such as by a jet pump 62 driven by the flash gas from flash tank 24, to be burned/combusted at burner 36' for regenerator 36 or in a flare 64.

In the prior art system of FIGS. 1 and 2, several possible drawbacks have been encountered. Since there is no positive means for causing flow of the water/BTEX vapor from regenerator 36 through the various possible components to condenser 46 and in turn to a three phase separator 52, other than possibly gravity and the expansion of the heating vapor in the regenerator, undesirable back pressure can develop in the system. This back pressure can have the result of causing build up of residues in the regenerator, and the build up of pressure can affect the boil off of the water/BTEX from the glycol, as well as the proper separation of the water, liquid BTEX and gaseous BTEX, in the separator.

In order to properly control the pressure in the regenerator/separator circuit, improved BTEX separation system 70 is provided, and illustrated in FIG. 3. Regenerator 36 is, as in the prior art configuration, fired by burner 37. A portion of the liquid water drawn off of separator 52 is directed to pump 72, which raises the pressure of the water to, for example, 50 psig. The flow rate and pressure of the water is further controlled by remotely controlled valve 74, which is controlled by thermocouple 75 and control means 81, which may include an appropriately programmed microprocessor, so as to maintain the pumped water pressure in a desired preselected range. Release of the water from separator 52, to pump 72, may also be controlled by the microprocessor, based upon the readings of other sensors in the system, such as temperature sensor 47.

It is also contemplated that system 70 include pressure sensor transmitter 100 operably associated with control means 81 and pump 72 for purposes of precluding the distilling column 101 of regenerator 36 from inadvertently collapsing. Accordingly, sensor 100 will continuously transmit the pressure within column 101 to control means 81. Should control means determine, for example, that the pressure within the column is too high (as a result of the draw caused by eductor 76), then the control means will alter pump 72 to, in turn, reduce the flow rate of the fluid being propelled therefrom.

The water is then sent through eductor 76, which may be installed adjacent vapor exit 38 of regenerator 36. The eductor 76 draws the water/BTEX vapor and entrains it in the pumped water flow. Eductor 76 has a venturi-type configuration, which causes a pressure drop to, for example, 5 psig, and exerts a partial vacuum to the flow of water/BTEX vapor 38 coming from regenerator 36. The pumped water, being at a substantially lower temperature than the water/BTEX vapor exiting regenerator 36, causes the condensation of at least some of the water/BTEX vapor. The pumped water, with the water/BTEX mix is then passed through heat exchanger/condenser 46 to cause further condensation of BTEX. vapor.

The pumped water, liquid BTEX, and entrained water/BTEX vapor are conducted to three phase separator 52, where the water, BTEX liquid and BTEX vapor separate substantially in the manner described with respect to the prior art system. The liquid BTEX can be drawn off, at 91, and stored in a storage chamber (not shown) at another location for subsequent utilization, in the manner previously described with respect to the prior art systems. BTEX vapor is then directed from the separator, through valve 80, to burner 37 where it is combusted (and broken down into non-harmful constituents) and accordingly used to heat regenerator 36.

In order to propel the BTEX vapor toward burner 37, the fuel gas is first inletted through valve 82, into the upper layer in separator 52, so that the fuel gas "sweeps" the BTEX gas out of separator 52. This enables a more continuous flow through the system, and prevents build up and possible reabsorption of the BTEX gas in the separator while facilitating the BTEX toward and into the burner for combustion.

When excess water has been collected in separator 52, a portion of the water, not needed to maintain proper volumetric flowrate through eductor 76, is released through a drain 90. A level control 77 may be connected to accumulator 78 to assure that a sufficient amount of water is maintained in the system to maintain the desired pressure, with adequate reserve, to replenish the system, when, for example, the flow rate is increased in response to commands by the control 81.

The system 70 is operably configured so as to maintain slightly higher pressure in separator 52, than in regenerator 36, so that the fuel and BTEX gases will further tend to flow from separator 52 to regenerator 36.

The foregoing description and drawings merely explain and illustrate the invention, and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention. 

We claim:
 1. A method for separating water, recovered during the dehydration of gas, from a dehydrating solution, the method comprising the steps of:a) distilling the water and various organic constituent vapors from the dehydrating solution; and b) positively sucking the distilled, predominantly vaporous water and various organic constituent vapors through and away from the distilling device by c) introducing a pressurized stream of fluid, from a source of fluid wherein the fluid has been collected and maintained within a range of volumes, into intersecting relationship with the distilled, predominantly vaporous, water and organic constituent vapor and d) exposing the distilled, predominantly vaporous, water to a partial vacuum associated with the pressurized stream so as to positively draw the water and organic constituent vapor from the distilling device into the pressurized stream; e) sensing the temperature of the flow of the distilled, predominantly vaporous, water and organic constituent vapors and pressurized stream of fluid mixture; f) controlling the flow of pressurized fluid, so as to increase the flow, if the sensed temperature is higher than a predetermined temperature, and so as to decrease the flow, if the sensed temperature is lower than a predetermined temperature.
 2. A method for separating water, recovered during the dehydration of gas, from a dehydrating solution, the method comprising the steps of:a) distilling the water and various organic constituent vapors from the dehydrating solution; and b) positively sucking the distilled, predominantly vaporous water and various organic constituent vapors through and away from the distilling device c) introducing a pressurized stream of fluid, from a source of fluid wherein the fluid has been collected and maintained within a range of volumes, into intersecting relationship with the distilled, predominantly vaporous, water and organic constituent d) exposing the distilled, predominantly vaporous, water to a partial vacuum associated with the pressurized stream so as to positively draw the water and organic constituent vapor from the distilling device into the pressurized stream; e) monitoring the level of the volume of fluid in the fluid source, used for the pressurized stream of fluid; f) controlling release of fluid from the fluid source into the flow of pressurized fluid so as to introduce more fluid when the level of fluid is lower than a predetermined level, and release fluid to a drain when the level of fluid is higher than a predetermined level.
 3. A method for separating water, recovered during the dehydration of gas, from a dehydrating solution, the method comprising the steps of:a) distilling the water and various organic constituent vapors from the dehydrating solution; and b) positively sucking the distilled, predominantly vaporous water and various organic constituent vapors through and away from the distilling device by c) introducing a pressurized stream of fluid, from a source of fluid wherein the fluid has been collected and maintained within a range of volumes, into intersecting relationship with the distilled, predominantly vaporous, water and organic constituent vapor; d) exposing the distilled, predominantly vaporous, water to a partial vacuum associated with the pressurized stream so as to positively draw the water and organic constituent vapor from the distilling device into the pressurized stream; e) sensing the pressure at the distilling device; and f) altering the flow rate of the pressurized stream of fluid in response to the pressure sensed. 